Part 2
EngineDisassembly (Steps 33-64)
33. Remove the RH high-pressure oil rail-to-valve cover gasket.
34. Remove the 4 bolts and the coolant pump pulley.
35. Remove the bolts and the coolant pump.
^ Discard the O-ring seal.
36. If equipped, remove the bolts and dual generator pulley.
37. Check the crankshaft vibration damper runout.
^ Remove the paint from the face of the crankshaft vibration damper at 4 points, 90 degrees apart.
^ Attach the special tool to the cylinder block. Position the special tool on one of the unpainted surfaces.
^ Using a suitable tool, pry the crankshaft forward. Zero the dial indicator.
^ NOTE: Pry the crankshaft forward at the same point to eliminate possible error caused by crankshaft end play.
Rotate the crankshaft 90 degrees. Pry the crankshaft forward. Record the measurement. Repeat at each unpainted surface.
^ If the runout exceeds specification, install a new crankshaft vibration damper.
38. CAUTION: To prevent engine damage, you must always install 4 new bolts when installing the vibration damper.
WARNING: To avoid personal injury, support the vibration damper during mounting bolt removal. The damper can slide off the nose of the crankshaft very easily.
Remove the 4 bolts and the crankcase vibration damper.
^ Discard the bolts.
39. Punch 2 holes in the crankshaft seal.
40. Using the special tool, remove and discard the crankshaft seal.
41. NOTE: The production engine will not have a wear sleeve.
If equipped, remove the crankshaft seal wear sleeve with the special tool.
^ Discard the crankshaft seal wear sleeve.
42. Remove the bolts and the oil pump body. Remove and discard the O-ring seal.
43. NOTE: Mark the front of each drive rotor for correct reassembly orientation.
Remove the inner and outer oil pump drive rotors.
44. Remove the bolts and engine front cover.
45. CAUTION: Sealant is used where the crankcase and lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the front cover gasket.
Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet. Remove and discard the front cover gasket.
46. Remove the flywheel adapter.
47. CAUTION: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.
Punch 2 holes across from each other in the crankshaft rear seal.
48. Using the special tool, remove and discard the crankshaft rear seal.
49. NOTE: Production engines will not have wear sleeve.
If equipped with a crankshaft wear sleeve, use the special tool to remove and discard the crankshaft rear wear sleeve.
50. Clean and inspect the crankshaft sealing surface.
51. CAUTION: To prevent engine damage, replace damaged or missing dowel pins before installing the rear engine cover.
Remove the 11 bolts from the rear engine cover.
52. CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the rear cover.
NOTE: A 5-1/2-inch long thin-blade scraper is needed to correctly cut the sealant.
Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet.
53. CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the rear cover.
NOTE: A 139.7 mm (5.5 inch) long thin-blade scraper is needed to correctly cut the sealant.
Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet.
^ Remove and discard the press-in-place gasket.
^ Clean and inspect the sealing surfaces.
54. Remove the crankcase-to-head tube assembly.
55. NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.
Remove the bolts and the high-pressure oil rail.
56. CAUTION: Use care not to deform the lower crankcase-to-head tube during removal. If the tube is damaged, a new tube must be installed.
NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing.
If the crankcase-to-head tube separated, using a pair of soft-jawed pliers, remove the lower crankcase-to-head tube.
^ Remove and discard the D-ring seal.
57. Remove and discard the D-ring seals.
58. CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
59. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
60. CAUTION: Failure to account for all snap rings or pieces of snap rings prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be ingested into the lube oil system causing severe engine damage.
CAUTION: To prevent engine damage, do not use air tools to remove the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.
NOTE: If engine oil is found in the engine coolant or engine coolant is found in the combustion chambers, new injector sleeves may need to be installed.
Remove the bolt, the fuel injector hold down and the fuel injector.
61. NOTE: If a snap ring or piece of a snap ring is missing from the injector hold-down assembly, it must be located prior to removing the shop towels.
Remove the shop towels.
62. NOTE: Left cylinder head shown, right cylinder head similar.
Remove and discard the 10 head bolts from each cylinder head.
63. Remove the 16 bolts and the rocker arm assemblies.
64. NOTE: Early build engines will have 8 rocker arm carrier-to-cylinder head bolts. Late build will have 2 rocker arm carrier-to-cylinder head bolts.
NOTE: Early build shown, late build similar.
Remove the rocker arm carrier from the cylinder head.
^ Remove the bolts.
^ Remove and discard the press-in-place gasket.
^ Clean and inspect the sealing surfaces.